Hybrid stand alone mattress system

ABSTRACT

A mattress system includes a subframe having fold joints. The subframe includes a foot section, a transition section, a body section, and a head section that are separated by the fold joints. The subframe includes an upper portion and a lower portion. The mattress system further includes a first strap and a second strap. The first strap extends through the foot section from the upper portion of the subframe to a lower portion of the subframe. The second strap extends through the foot section from the lower portion of the subframe to an upper portion of the subframe such that the first and second straps form an X.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 63/059,452, filed Jul. 31, 2020, the entire contents of which are incorporated by reference herein.

BACKGROUND

It is generally known that foldaway or foldable beds are attractive bedding options for persons with restricted living space, such as are commonly found in recreational vehicles, trailers, boats, studio apartments, and the like. A Murphy-style bed includes a mattress that can be swung or folded into a wall-mounted cabinet or closet when not being used for sleeping. A convertible foldable bed folds upon itself, either one or two times, for compact storage to serve as a sofa or seating area, and then is unfolded into a bed for sleeping. The convertible sofa-bed includes a mattress that is sufficiently flexible to fold upon itself, and that is supported and deployed by an articulated bed frame.

Although generally satisfactory for their intended purposes, the known foldable beds have exhibited some drawbacks. For maximum sleeping comfort, the mattress is desired to be relatively firm and thick. However, a thick, firm mattress is not readily foldable, and particularly not in furniture of contemporary style where a low seat height and small dimensions are aesthetically desirable. In foldaway beds, a thick mattress requires a deeper cabinet or closet, thereby encroaching on the already limited living space. Where style and space requirements are paramount, a thin, foldable, soft, and easily crushable mattress is employed; however, the result is often an unsatisfactory, uncomfortable sleeping surface.

To solve the aforementioned problems, several internal spring systems within mattresses have been developed, the systems being foldable for compact storage and being unfoldable for resiliently supporting a person during use. Reference can be made, for example, to such earlier U.S. patents as, namely, U.S. Pat. Nos. 4,489,450; 4,654,905; 4,620,336; 5,184,809; 5,431,376; 5,535,460; 5,539,940; 5,539,944; 5,540,418; 5,524,305; 5,642,536; 5,655,240; 7,487,564; 7,726,636; and 7,979,930.

As exemplified by some of these patents, each internal spring system has an upper wire grid located below, and in proximity with, an upper mattress face; a lower wire grid located above, and in close proximity with, a lower mattress face; and a plurality of generally planar, sinuous springs, each pivotably connected at opposite ends thereof to the respective upper and lower grids of the internal spring system. When the mattress is in the open or body-supporting position, the sinuous springs stand vertically upright in parallel planes generally parallel to head and foot end faces of the mattress, and resiliently hold the upper and lower grids apart. However, as the mattress is folded to the closed or storage position, the pivotable springs pivot about the grids and lie in inclined planes; and, at the same time, the upper and lower grids shift longitudinally and are drawn closer together, thereby decreasing the distance between the upper and lower mattress surfaces and decreasing the thickness of the mattress so that the mattress can be compactly stored within the furniture cabinet or closet in the closed position.

Experience has shown, however, that the longitudinal shift between the upper and lower grids is disadvantageous, because this shift must be accommodated in the mattress itself, as well as in the furniture cabinet or closet. For example, if the upper and lower grids have the same length as considered lengthwise or longitudinally of the mattress, then the upper grid would shift longitudinally forwardly during movement to the closed position. The shifted upper grid occupies more space that would undesirably increase the interior space required within the furniture cabinet or closet.

In addition, the known mattresses having such sinuous springs tend to collapse in the open position, that is, they cannot readily stand erect by themselves without having to somehow anchor it to a support outside the mattress to maintain vertical stability, and/or by using internal webbing straps to resist such collapse.

SUMMARY

According to one aspect, this disclosure is directed to a mattress system including a subframe, a first strap, and second strap. The subframe has fold joints and includes a foot section, a transition section, a body section, and a head section that are separated by the fold joints. The first strap extends from the foot section to the body section. The second strap is secured to the foot section and is disposed transverse to the first strap.

In aspects, the first and second straps may have different lengths. The first strap may be longer than the second strap.

In aspects, the foot section may include a border wire to which a first end of the first strap connects. A second end of the first strap may connects to a cross wire in the body section. The first end of the first strap may be positioned higher than the second end of the first strap such that the first strap extends in a first direction at an inclined angle. The second strap may extend in a second direction at an inclined angle, the first and second directions being different.

In aspects, the second strap may have a first end that connects to a cross wire in the foot section. The second strap may have a second end that connects to a first fold joint of the fold joints. The first fold joint may be disposed between the foot section and the transition section.

In aspects, the subframe includes sinuous springs supported in the foot section and coils supported in at least one of the transition section, the body section, or the head section of the subframe.

According to another aspect, this disclosure is directed to a mattress system including a subframe, a first strap, and a second strap. The subframe has fold joints and includes a foot section, a transition section, a body section, and a head section that are separated by the fold joints. The subframe includes an upper portion and a lower portion. The first strap extends through the foot section from the upper portion of the subframe to a lower portion of the subframe. The second strap extends through the foot section from the lower portion of the subframe to an upper portion of the subframe such that the first and second straps form an X.

In aspects, the second strap may have a second end that connects to a first fold joint of the fold joints, the first fold joint disposed between the foot section and the transition section to enable relative movement between the foot section and the transition section.

In aspects, the subframe may include sinuous springs supported in the foot section. The subframe may include coils supported in at least one of the transition section, the body section, or the head section of the subframe.

In aspects, a second fold joint extends between the transition section and the body section to enable movement between the transition section and the body, and wherein a third fold joint extends between the body section and the head section to enable movement between the body section and the head section.

Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims that follow.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate aspects of the disclosure and, together with a general description of the disclosure given above and the detailed description given below, explain the principles of this disclosure, wherein:

FIG. 1 is a top view, with portions removed for clarity, of a hybrid stand-alone mattress system in accordance with the principles of this disclosure;

FIG. 2 is a side view of FIG. 1;

FIG. 3 is a perspective view of the mattress system of FIG. 1 laying on and attached to a subframe and positioned on a deck attached to a sofa bed mechanism, the view further illustrating a telescopic extender of the mattress system in an open state;

FIGS. 4 and 5 are enlarged, perspective views of portions of the mattress system of FIG. 1;

FIG. 6 is a perspective view of straps of the mattress system of FIG. 1;

FIGS. 7A-7E are various views of a wire form of the mattress system of FIG. 1;

FIGS. 8 and 9 are perspective views of the mattress system in folded positions;

FIG. 10 is a perspective view of the mattress system of FIG. 1;

FIG. 11 is a perspective view illustrating mattress retainers attached to a head tube;

FIG. 12 is a perspective view with the mattress system shown right side up and illustrating top strapping secured to lower subframe connections;

FIG. 13 is a perspective view with the mattress system shown upside down from a head section angle; and

FIG. 14 is a perspective view with the mattress system shown upside down, from the head section angle, and illustrating the subframe sections and the mattress retainers inserted into the head tube.

DETAILED DESCRIPTION

Aspects of the disclosed systems and methods are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. In the following description, well-known functions or constructions are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

With reference to the FIGS. 1-14, this disclosure details a hybrid stand-alone mattress system 1 that will stand erect in or out of a sofa bed mechanism “M.” The mattress system 1 includes a mattress 2 with a subframe 10 (e.g., 57.5 inch width and 73.25 inch length) having three fold joints 12 a, 12 b, 12 c that define a foot section 14 (e.g., 23.5 inches), a transition section 16 (e.g., 8.75 inches), a body section 18 (e.g., 27.75 inches), and a TV or head section 20 (e.g., 13.25 inches). Each section has a spot welded, rectangular wire (or comparable material) grid 14 a, 16 a, 18 a, 20 a going side to side and to one or more of the respective fold joints 12 a, 12 b, 12 c. A side of each grid section can be used as a mattress border wire 21 that will attach to an outside coil.

The subframe 10 further includes internal support grid wires 26 that may be equally spaced apart from one another. The support grid wires 26 are attached to each other with clips or other means to hold them together and enable the mattress 2 to rotate about fold joints 12 a, 12 b, 12 c (such as sewing a helical across a three-wires joint which maintains joint position but allows rotation).

In foot section 14 of mattress 2, foot section grid 14 a is attached to the outside edge of the mattress 2 and goes across the mattress 2 to frame the vertical or sinuous springs 22 (e.g., a Miller spring that has a planar configuration with multiple switchbacks and is pivotable between vertical and inclined/flat positions) found in the foot section 14 of mattress 2. The foot section grid 14 a has support wires 24 that run in the head to foot or longitudinal direction.

The foot section 14 also includes an end extender 28 that adds rigidity to hold length and shape to the bottom of the mattress 2. End extender 28 defines a pocket in which the vertical springs 22 rest when folding of mattress 2 occurs. The foot section 14 further includes a telescopic extender 30 to facilitate elongation of the mattress 2.

Subframe 10 further includes internal X straps 32 (e.g., four short X straps 32 a, four long X straps 32 b—see FIG. 6) and which extend between sides of mattress system 1. Internal X straps 32 are positioned close to the internal support grid wires 26 and are anchored to the subframe 10 (e.g., at a spring surface). The long X straps 32 b attach at one end to end border wire 21 at the top of foot section 14, and at the other end, down to internal subframe cross wire 34 in body section 18. The short X straps 32 a attach at one end to a bottom cross wire 36 in foot section 14 and extend up to an upper portion of fold joint 12 a where sinuous springs 22 join Bonnell springs 38 at fold joint 12 a. As best seen in FIG. 2, the X straps 32 hold the sinuous springs 22 in the foot section 14 in a vertical orientation when the mattress 2 is in an erect or vertical bedding mode. The X straps 32 are spread out from each other, side-to-side, to maintain top surface resistance when under surface weight. The X straps 32 provide easy attachment and include added hog rings and/or clips 33, which may have wire formed ends. For instance, the long X straps 32 b have an open wire formed end 33 w that enables quick snap on attachment to wires, springs, etc. And the short X straps 32 a have two wire form ends, a first wire form end with a clip 33 f (e.g., metal) and second open wire form 33 g that enables quick snap on attachment to wires, springs, etc. The X straps 32 may include any suitable material such as plastic, poly, wire, metal cord, chain, etc.

In aspects, one form can be added to the strap ends and shaped as an open-ended square loop. This can be secured by a clip to internal support wire 26, or clip to a foot section, top wire that extends side-to-side of mattress 2.

In aspects, only one end of short X straps 32 a may include a wire form end made with a double U-shape. The double U-shape can be hooked over the upper connection of the foot and Bonnell spring side to a fold joint. A hog ring can be added to prevent the U-shapes from opening.

Subframe 10 further includes head wire forms or mattress retainers 40 positioned at the end of the head section 20 to prevent the mattress system 1 from pushing over and past the head tube 42. These mattress retainers 40 hook to helical deck connections 44 of mattress system 1 (which by design go beyond some sofa bed frames configured to allow the mattress itself to go over head tube 42). If a deck 46 (e.g., polypropylene) of the mattress system 1 is high, mattress retainers 40 provide a back stop for the mattress 2 to push against and to force mattress 2 to fold at its fold joints 12 a, 12 b, 12 c. Where the deck 46 is below the head tube 42, the mattress 2 will push against the head tube 42 to force folding of the mattress system 1.

When folding the mattress 2 at the fold joints 12 a, 12 b, 12 c, the mattress 2 takes the shape of a sofa or a chair shape. Without subframe 10, the edges of the deck 46 of the folded mattress 2 would be rounded (e.g., as the front of a toboggan). The mattress system 1 of this disclosure enables edges of the rigid subframe 10 to square off the deck 46 at angles when folded to open an internal mattress storage compartment.

FIG. 4 illustrates a helical 50 spun side-to-side to catch both the edge of a rounded Bonnell coil 38 and a flat side of a wire mesh (channel shaped) to hold the foot section 14. Also, there is a straight wire 52 (e.g., spring steel) slide into the center of the helical 50 which aligns and acts as a pivot when the mattress system 1 folds. This connection is used on both the top (or upper portion) and bottom (or lower portion) of the mattress 2 to secure various springs together. For instance, an X strap 32 x snaps and attaches to the edge of a connection 48 between a top wire mesh and a Bonnell spring 38. The connection 48 is located at the helical 50 with the straight wire 52 centering the helical 50. An X strap 32 y connects to a cross wire (side-to-side) of a lower portion of subframe 10 by a clip.

In FIG. 5, the mattress 2 is upside down and the subframe is shown attached to an X strap 32 with a metal clip 33 a. This view illustrates bottom subframe sections clipped together at folding joints and with a lower end of an X strap 32 seen clipped to a side-to-side wire of the lower portion of subframe 10 to anchor the X strap 32 and to hold foot section 14 a in a vertical orientation.

FIGS. 7A-7E illustrate mattress retainers 40 of this disclosure that have open ends to attach to head tube 42 or slide into the helical end loops that hold and position the deck 46 at the head of the mattress 2. These mattress retainers 40 allow the mattress 2 to extend over and forward of the sofa bed mechanism “M” (and hold the mattress 2 in position). Mattress retainers 40 function to raise head section 20 of the mattress 2 slightly (e.g., to provide a slight lift or pillow when laid upon). Together mattress retainers 40 and head tube 42 (wire bracket) add and control length and support to the head section of the mattress 2. Also, mattress retainers 40 and head tube 42 prevent the mattress 2 from pushing or sliding forward when the unit is folded to a stored position. Mattress retainer 40 includes hooked ends 40 a (e.g., 2 inches) that hold the deck 46 in place. Mattress retainer 40 has a width (e.g., 9 inches) sufficient to act as a stop surface that prevents mattress movement. As seen in FIG. 7B, hooked ends 40 b can have an alternative configuration to hold the deck 46 in place. As seen in FIG. 7C, mattress retainer 40 can have a gradual incline to a final inclined stop surface 40 d.

With reference to FIG. 8, because of the small low storage space allowed for bedding, mattress system 1 includes a sufficiently soft sofa bed to enable the mattress 2 to compact when stored. The mattress system 1 includes shorter height coils, reduced foam, and less coils to allow the mattress 2 to be compacted into a shallow space without bulging upward or destroying the mechanism. In aspects, any suitable sized coil may be used. Because the foot section 14 a folds on the body section 18 (5¼ inches on top of 5¼ inches plus padding material), the mattress system 1 may provide 5¼ inches on top of ⅜ inch plus padding. The internal X strapping to the hinged subframe 10 allows the finished mattress (e.g., 9 inches tall) to function and be compatible with existing manufactured sofa beds (forcing the existing flimsy decks 46 to an exact storage shape and providing a flat deck for seating). In aspects, the internal X straps secured to the hinged subframe 10 can also be used outside of the sofa bed mechanism, for example, on the floor. Normally, when all sofa beds are folded up to store, the front of the folded mattress takes a general rounded frontal shape (e.g., of a toboggan), but the disclosed subframe of mattress system 1 is configured to provide a squared off front and rear shape “SQ” to enable much more storage mattress space and to provide a flat seat.

With reference to FIG. 9, the mattress 2 is shown being forced to fold forward against the retainers causing the coils to collapse on to one another as the outside or bottom subframe demands the mattress 2 to conform to the limiting wire subframe. This allows the mattress 2 to be longer over the head tube 42. This view also illustrates that the telescopic extender 30 on the foot section 14 will have a shorter length when stored, and a longer length when used as a bed.

With reference to FIG. 10, the telescopic extender 30 aides in the vertical stability of mattress 2. The telescopic extender bridges over three rows of foot coils to produce a much firmer foot when one is sitting on foot section 14. Advantageously, the disclosed telescopic extender 30 includes a single top mattress surface slide rods that bridge over three side-to-side rows of springs to add firmness when one sits on the foot section 14 of the mattress system 1. FIG. 11 shows the mattress pulled back and illustrates the retainers 40 extending the mattress. FIG. 12-14 illustrate various features and views of the mattress system 1 including deflectable push-pull spring wires 55 that deflect when depressed.

For a more detailed description of a related mattress system, one or more components of which may be included or modified for use with the disclosed mattress system, reference can be made, for example, to U.S. Pat. No. 10,610,026, the entire contents of which are incorporated by reference herein.

As can be appreciated, securement of any of the components of the disclosed apparatus can be effectuated using known securement techniques such welding, crimping, gluing, fastening, etc.

Persons skilled in the art will understand that the structures and methods specifically described herein and illustrated in the accompanying figures are non-limiting exemplary aspects, and that the description, disclosure, and figures should be construed merely as exemplary of aspects. It is to be understood, therefore, that this disclosure is not limited to the precise aspects described, and that various other changes and modifications may be effectuated by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, it is envisioned that the elements and features illustrated or described in connection with one exemplary aspect may be combined with the elements and features of another without departing from the scope of this disclosure, and that such modifications and variations are also intended to be included within the scope of this disclosure. Indeed, any combination of any of the disclosed elements and features is within the scope of this disclosure. Accordingly, the subject matter of this disclosure is not to be limited by what has been particularly shown and described. 

What is claimed:
 1. A mattress system, comprising: a subframe having fold joints, the subframe including a foot section, a transition section, a body section, and a head section that are separated by the fold joints; a first strap that extends from the foot section to the body section; and a second strap that is secured to the foot section and is disposed transverse to the first strap.
 2. The mattress system of claim 1, wherein the first and second straps have different lengths.
 3. The mattress system of claim 2, wherein the first strap is longer than the second strap.
 4. The mattress system of claim 1, wherein the foot section includes a border wire to which a first end of the first strap connects.
 5. The mattress system of claim 4, wherein a second end of the first strap connects to a cross wire in the body section.
 6. The mattress system of claim 5, wherein the first end of the first strap is positioned higher than the second end of the first strap such that the first strap extends in a first direction at an inclined angle.
 7. The mattress system of claim 6, wherein the second strap extends in a second direction at an inclined angle, the first and second directions being different.
 8. The mattress system of claim 1, wherein the second strap has a first end that connects to a cross wire in the foot section.
 9. The mattress system of claim 8, wherein the second strap has a second end that connects to a first fold joint of the fold joints, the first fold joint disposed between the foot section and the transition section.
 10. The mattress system of claim 1, wherein the subframe includes sinuous springs supported in the foot section and coils supported in at least one of the transition section, the body section, or the head section of the subframe.
 11. A mattress system, comprising: a subframe having fold joints, the subframe including a foot section, a transition section, a body section, and a head section that are separated by the fold joints, the subframe including an upper portion and a lower portion; a first strap that extends through the foot section from the upper portion of the subframe to a lower portion of the subframe; and a second strap that extends through the foot section from the lower portion of the subframe to an upper portion of the subframe such that the first and second straps form an X.
 12. The mattress system of claim 11, wherein the first and second straps have different lengths.
 13. The mattress system of claim 12, wherein the first strap is longer than the second strap.
 14. The mattress system of claim 11, wherein the foot section includes a border wire to which a first end of the first strap connects.
 15. The mattress system of claim 14, wherein a second end of the first strap connects to a cross wire in the body section.
 16. The mattress system of claim 15, wherein the second strap has a first end that connects to a cross wire in the foot section.
 17. The mattress system of claim 16, wherein the second strap has a second end that connects to a first fold joint of the fold joints, the first fold joint disposed between the foot section and the transition section to enable relative movement between the foot section and the transition section.
 18. The mattress system of claim 17, wherein the subframe includes sinuous springs supported in the foot section.
 19. The mattress system of claim 18, wherein the subframe includes coils supported in at least one of the transition section, the body section, or the head section of the subframe.
 20. The mattress system of claim 19, wherein a second fold joint extends between the transition section and the body section to enable movement between the transition section and the body, and wherein a third fold joint extends between the body section and the head section to enable movement between the body section and the head section. 